2004 DACIA SOLENZA Repair Manual

TRANSM ISSION
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Front transversal transmission
REMOUNTING – THE SIDE TO THE GEARBOX
The left side
Engage the transmission GI joint in the gearbox (the transmission position as horizontally as
possible).
Mount the three attachment screws of the bellows l id on the gearbox.
The right side
Grease the tulip frame grooves (the grooves area) and the transmission shaft of the gearbox
with transmission oil.
Engage t he tra nsmission GI joint (t he tulip) on the transmission shaft of the ge arbox (the
transmission position must be as horizontally as possible).
REMOUNTING – THE SIDE TO THE WHEEL
For both sides
Engage the transmission in the steering knuckle, this one being necessary to freely enter, so that
threaded area of the steering knuckle is allowin g to remounting the transmission nut.
Perform then the dismounting operations in the reverse order.
Observe the tightening moments.
Remount the brake disk assembly.
Refill the gearbox with oil.
Press several times the brake pedal to enable caliper piston coming in contact with the brake
pads.
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Bellows - Bearing assembly
to th e gearbox
THE JOINT TO THE GEARBOX - GI
SPECIAL TOOLS
Bearing mounting chuck on the shaft PF 1331
1. Tripod assembled
2. Bellows
3. bearing
4. bellows attachmen t lid
5. deflector
6. blocking ring
7. transmission shaft
DISMOUNTIN G
It is forbidden to use thinner for components
parts cleaning.
Dismount the blocking ring from the groove
made on the transmission shaft, using a special
pincers for these types of rings.
Left
transmission
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Bellows - Bearing assembly
to th e gearbox
Using a press, extract the assembled tripod,
sustained it on an extractor, FACOM U 53 G
type, protecting the tripod clogs.
Before extracting, mark the position of the
tripod compared to the transmission shaft end.
Dismount the bellows - deflector bearing in
the same manner like tripod dismounting .
REMOU NT I NG
In order to be corre ctly positioned on the
s haft, the bearing must be pressed to achieve
the value L = 118 ± 0.2 mm between the
backside of the bearing and the shaft extremity.
This value is obtained by means of the PF 1331
device, when mounting, its extremity is at the
level of the shaft.
IMP ORTANT:
In order to avoid the deformation of the bearing, which includes a sealing gasket
(annular oil seal), the pressing effort must be constant (do not hammer).
Left
transmi ssion
GPF
1331
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Bellows - Bearing assembly
to the gearbox
Maintaining the transmission on the press, on both sides, shall be ensured on the G groove
made on shaft, by means of a device t ype FACOM U 53 G, ( the flat side towards bellows) in
order to avoid the deflector damages on the wheel side. The pressing effort of the bearing on the transmission shaft ahas the value of = 100 – 700
daN. Press again the assembled tripod on the transmission shaft observing the marks made when
depressing. The press effort of the tripod assembly on the grooved area of the shaft end, shall be between
60 – 600 daN. Remount the blocking ring (Zeger lock) in the groove made on the transmiss ion shaft.
Left
transmi ssion
G
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Bellows to wheel
JOINT TOWARDS WHEEL
1. Steering knuckle casing ass.
2. Retainer star
3. Tripod to the wheel
4. Tulip shaft
5. Maintai ning collars
6. Rubber protection bellow SPECIAL TOOLS
GE 86 joint bellows replacement device PF 537-04
DISMOUNTIN G
Dismount the two maintaining collars off
the bellows by means of two rods, locally
manufactured (see the drawing)
Cut and remove the damaged bellows.
Remove as much grease as possible.
Mark one of the groove routes of the shaft
subject to its working corresponding clog by
marking w ith a centre punch on casing outer
conse quently on the shaft.
Detach th e connection be twe en the
transmission shaft and the steering knuckle
casing, lift ing one by one the arms of the
reta ining star from the three stamps performed
on the petals of the shaft tulip.
WHEN DISMOUN TIN G, DO N OT
DEFORM THE ARMS OF THE RETAINING
STAR
Retrieve the head and the spring from the
tripod to wheel.
Left
transmi ssion
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Bellows to wheel
REMOUNTING
The mounting of the new bellows is to be
performed by means of the PF 573 – 04 device.
Catch the inclined transmission in a vice with
soft jaws in order to avoid the shaft damaging.
Engage the PF 537 – 04 device over the tulip
of the transmission shaft.
O bturate the small e xtremity of the bellows
and, abundantly grease with automatic
transmission oil or ELF CARDREXA RNT 2
grease: - the all outer surface of the PF 537 – 04
device, - the inner part of the bellows, especially its
smaller diameter part (this operation is performed
for slipping help).
Left
transmi ssion
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Bellows to wheel
Introduce the smaller di ameter of the
bellows on the PF 537 – 04 device.
Cover a hand with clean gauze and place
it on t he bellows in such a way as to stretch
the first fold.
T ake support with the hip on the e dge of
the vice (lateral side). Place the ot her hand around the first one
and strongly pull it, taking care that first fold
is not huddled together. Bring the bellows as close as possible to
the device cylindrical part and let it release till
half stroke.
It is recommended to perform many times
this operation (maximum 5 times).
When e asy slipping i s noticed, make so
that bellows is passing ove r the de vice
cylindrical part, the operation being
performed without stopping.
Left
transmi ssion
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Bellows to wheel
Catch the steering knuc kle c asing in a vice
with soft jaws. Put the spring and head in the tripod groove.
Brings the clogs to the center.
Position the retaining star ( S), and each of its
arms, being at the bisecting lines of the a ngles
formed by the tripod arms.
Introduce the transmission shaft in the steering
knuckle casing, positioning it, subject to the
marks (the t hree c logs penetra ting in the t hree
rolling routes of the shaft). Slide slowly the t ransmission shaft, in order
to engage one arm of the retaining star in the
marked point of the transmission shaft, and press
it for correct centering.
Placing the other retaining star t wo arms, it
will be made easy by a screwdriver, with its end
modified as per drawing:
A = 5 mm B = 3 mm
Ensure that retaining star arms are correctly
positioned in the shaft marks.
Check by hand, the joint operation.
Must not exist any hard point.
Di stribute in the bellows and in the steering
knuckle casing the grease prescribed dosage.
NOTE It is obligatory to observe the quantity
and type of the prescribed grease, 2 l
+1 cl,
ELF CARDREXA RNT 2.
Left
transmi ssion
S
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